Adjustable stapler and methods associated therewith

ABSTRACT

Disclosed herein is a stapler for forming staples according to a thickness of a stack and clinching the stack with at least one of the formed staples.

BACKGROUND

One of the most common devices found in offices all over the world isthe stapler. Staplers have been used for years to fasten a plurality ofsheets of media together using a thin, U-shaped piece of wire, which isknown as a staple. The base of the U-shaped staple is known as thecrown, with the legs of the U forming the staple legs. Sheets of mediato be fastened together are placed on top of a clinching anvil havingrecesses formed in the top side thereof. The recesses function as aforming tool to form clinches on the bottoms of the legs, therebyfastening the plurality of sheets of media together.

A cassette designed to hold a plurality of staples therein isconventionally used to supply the stapler with staples. Staples disposedin the cassette are biased toward an end of the cassette, which islocated over the clinching anvil. The cassette supports the plurality ofstaples on a bottom side of the crowns of the staples, with a singlestaple extending into a fixed slotted aperture located in the end of thecassette. The slotted aperture is located over the anvil, with theslotted aperture being aligned with the recesses in the clinching anvil.The staple extending into the slotted aperture in the end of thecassette is unsupported on the bottom side of its crown.

A driving member, which is typically a thin driving blade, extends intothe slotted aperture from the top of the cassette. The driving member islocated above the staple extending into the slotted aperture in the endof the cassette. The driving blade is driven into contact with the topside of the crown of the staple extending into the slotted aperture inthe end of the cassette. The driving blade may then drive the staplelegs into and through the plurality of sheets of media located adjacentto the clinching anvil. After the staple legs pass through the media,the legs contact the recesses disposed in the top side of the clinchinganvil. When the staple legs extend into the recesses in the clinchinganvil, they are clinched, typically towards each other, to therebyretain the staple in the plurality of sheets of media to keep theplurality of sheets of media together.

The driving blade is driven by hand in simple desktop staplers, oftenwith a single swift impact from the user's hand. This impact is usuallymore than sufficient to drive the staple into the sheets of media and toclinch it on the bottom of the media. In a slightly more sophisticatedstapler, the impact is provided electromechanically. Sheets of media maybe inserted into position against the clinching anvil at which time anelectrical trigger may cause operation of the driving blade. Inheavy-duty industrial applications, a stapler may even be operated usingpneumatic pressure to operate the driving blade.

Many conventional staplers have at least one cassette containing a rowof preformed staples of a particular size (i.e. the staples are alreadybent into a generally U-shaped configuration). Most conventionalstaplers are designed to drive a staple of one particular leg size only,with that size staple being best applied to use to fasten together aspecific range of numbers of sheets of media.

For example, a short leg (one-quarter inch, for example) staple may beused to fasten from two to twenty-five sheets of standard 20# mediatogether. If a greater number of sheets of media are to be fastenedtogether using a short staple, they will not be fastened togethersecurely because the staple legs are too short. Similarly, a long leg(three-quarter inch, for example) staple may be used to fasten fromfifty to one hundred and fifty sheets of standard 20# media together. Ifa smaller number of sheets of media are to be fastened together using along leg staple, the staple legs will be over-clinched. An over-clinchedstaple may have legs that extend through the sheets of media in anundesirable manner.

SUMMARY

In one exemplary embodiment disclosed herein, an apparatus and methodmay include: providing a stapler; forming at least one first staple inthe stapler; forming at least one second staple in the stapler; whereineach of the first and second staples has at least a pair of leg portionsjoined by a crown portion and wherein the crown portion defines a crownlength; and wherein the crown length of the first staple is differentfrom the crown length of the second staple.

BRIEF DESCRIPTION OF THE DRAWING

Illustrative embodiments are shown in Figures of the drawing in which:

FIG. 1 shows a schematic illustration of a process for forming a stapleand clinching a stack of media.

FIG. 2 shows a top plan view of a stack of media clinched by a staple.

FIG. 3 shows a cross-sectional view, taken across plane 3—3 of FIG. 2,wherein the stack of media is clinched by the staple.

FIG. 4 shows a side elevation view of an exemplary staple.

FIG. 5 shows a perspective view of an exemplary staple.

FIG. 6 shows a perspective view of one type of preform cartridge fromwhich preforms may be supplied.

FIG. 7 shows a perspective view, in an exploded state, of an exemplarystapler utilized for forming staples and clinching stacks.

FIG. 8 shows a front elevation view of the exemplary stapler of FIG. 7.

FIG. 9 shows a side elevation view of the exemplary stapler of FIG. 7.

FIG. 10 shows a front elevation view of an exemplary forming anvil anddie assembly of an exemplary stapler for forming a staple from apreform.

FIG. 11 shows a front elevation view of the exemplary stapler shown inFIG. 10 after the staple is formed from the preform.

FIG. 12 shows a front elevation view, with a partial cross-section of anexemplary clinching anvil, of an exemplary stapler while a staple isbeing driven into a stack of media.

FIG. 13 shows a front elevation view, with a partial cross-section of astack, wherein the stack of media is clinched with a staple.

FIG. 14 shows a front elevation view of an exemplary stapler wherein astaple is subjected to a force, thereby placing the staple into abuckling condition.

FIG. 15 shows a perspective view of an exemplary multiple-preformstaple.

FIG. 16 shows a top plan view of a stack of media clinched by anexemplary multiple-preform staple.

FIG. 17 shows a top plan view of an exemplary variable staple aperture.

FIG. 18 shows a front elevation view of the variable staple aperture ofFIG. 17.

FIG. 19 shows a side elevation view of an adjustable driving assembly.

FIG. 20 shows a schematic diagram of an exemplary imaging systemprovided with a stapler.

DETAILED DESCRIPTION

Staplers may be provided as an integral component of printing and/orbinding devices such as printers, copy machines, facsimile machines,automated folding machines, etc. Staplers may also be provided asstand-alone products that are operated either manually orelectromechanically. The present disclosure describes an automatedstapler contained within a printer for exemplary purposes. It is to beunderstood, however, that the apparatus and methods disclosed herein mayalternatively be utilized in conjunction with any of the devicespreviously mentioned or other equipment in which media is handled.

FIG. 1 illustrates a process in which staple preforms 83 are used tosecure a stack 32 of media. As will be explained in further detailherein, a coil 82 of staple preforms 83 may be fed from a cartridge 80into a stapler 100 (FIGS. 7, 8, 9 and 18). The stapler 100 converts oneof the preforms 83 (e.g. preform 84) into a generally U-shaped staple 40(also shown, for example, in FIG. 4) before being utilized to clinch thestack 32 of media. Thereafter, the stapler 100 drives the staple 40 intothe stack 32 of media and clinches it in place (as also generally shownin FIGS. 2 and 3) in order to secure the media together. Accordingly,the stapler 100 is capable of accepting straight preforms 83, convertingthese to U-shaped staples (e.g. staple 40) and driving and clinchingthese staples in order to secure together a stack of media, such as thestack 32. In a process that will be described herein, the staple 40 canbe formed from the preform 84 according to the thickness of the stack 32of media. In particular, a crown length L1 may be determined and formedaccording the thickness of the stack 32. By varying the crown length L1,a leg length L2 is modified in a manner that will be described herein.

With reference to FIG. 2, the stack 32 is shown clinched by the staple40. As used herein, the term ‘clinch’ means securing individual items(e.g. sheets of media) to each other. The staple 40 may, for example, belocated near a corner 36 of the stack 32 as illustrated in FIG. 2. As analternative, the staple 40 may be located at any other location on thestack, such as, for example, a spine of a pamphlet, a top edge of thestack 32, or other locations that those skilled in the art willappreciate.

With reference to FIG. 3 illustrating a cross-sectional view of thestack 32 taken across plane 3—3 of FIG. 2., the staple 40 may include acrown 50, a first leg 52 and a second leg 54. The first and second legs52, 54 may be attached to (e.g. integrally formed with) the crown 50.The staple crown 50 may have a first distal end 51 and an oppositelydisposed second distal end 53. The first distal end 51 of the crown 50may have a first bend 56 formed therein. The second distal end 53 of thecrown 50 may have a second bend 58 formed therein. The first leg 52 maybe attached to the crown 50 at the first bend 56. The second leg 54 maybe attached to the crown 50 at the second bend 58.

FIG. 4 illustrates the staple 40 in a condition before it has beenclinched. This staple 40 may define a first distal end 62 and a seconddistal end 64. The first distal end 62 may be located on the first leg52. The second distal end 64 may be located on the second leg 54. Thestaple 40 may be provided with a first penetrating end 63 formed on thefirst distal end 62. The staple 40 may also be provided with a secondpenetrating end 65 formed on the second distal end 64. The penetratingends 63, 65 may take the form of ‘points’. Each point may, for example,be formed as a tapered reduction in the cross-sectional area of therespective leg.

With continued reference to FIG. 4, the crown 50 may define a crownlength ‘L1’. The first and second legs 52, 54 may be substantially equalin length, this leg length is denoted by ‘L2’. In a process that will bedescribed herein, these lengths L1, L2 will be created according to thethickness of a stack to be clinched.

FIG. 5 also illustrates the staple 40 in the condition before it hasbeen clinched. The staple crown 50, first leg 52 and second leg 54 mayhave substantially uniform cross-sectional profiles because they may beformed from a preform (e.g. preform 84, FIG. 6). This cross sectionalprofile of the staple 40 may define a preform width ‘L4’ and a preformthickness ‘L5’. In one exemplary, non-limiting embodiment, the preformwidth L4 may be about 0.020 inches and the preform thickness L5 may beabout 0.015 inches. It is noted that the preform width L4 and thepreform thickness L5 are provided for illustrative purposes only andthat other dimensions may be utilized depending on the particularapplication, staple material, properties of the media, etc.

With reference again to FIG. 3 showing a cross-sectional view takenacross plane 3—3 of FIG. 2, the stack 32 may be clinched with the staple40. In a process to be described later herein, the stack 32 may befastened by forming a first clinch 72 and a second clinch 74 in thestaple 40. The first clinch 72 may be formed in the first distal end 62.The second clinch 74 may be formed in the second distal end 64. Thestack 32 may be secured between the crown 50 and the clinches 72, 74.

With reference to FIG. 6, the staple cartridge 80 may be provided forsupplying staple preforms 83 to the stapler 100 (FIGS. 7, 8, 9 and 18).As shown in FIG. 6, the cartridge 80 may include the coil 82 of theplurality of staple preforms 83 such as individual preforms 84, 86, 88,90, etc. The preforms 83 may be supplied from the cartridge 80 into thestapler in an unbent, relatively straight configuration defining thepreform length L3. These preforms 83 may be adhered to each other by anyone of a variety of adhesives. Cartridges, such as cartridge 80, arewell known in the art, such as those documented in the followingreferences: U.S. Pat. No. 5,454,503, to Udagawa et al.; U.S. Pat. No.5,346,114, to Udagawa et al.; U.S. Pat. No. 3,602,414, to Garfinkel;U.S. Pat. No. 5,560,529 to Udagawa et al.; U.S. Pat. No. 3,279,673, toSchafroth et al.; U.S. Pat. No. 5,273,199 to Logtens; U.S. Pat. No.3,009,618 to Lerner; and U.S. Pat. No. 5,676,299 to Yoshie et al., whichare all hereby specifically incorporated by reference for all that isdisclosed therein.

FIGS. 7-9 show one exemplary type of stapler 100 that may include aforming anvil 110, a die assembly 160, a clinching assembly 200 and adriving assembly 230 and an aperture 260.

With reference to FIG. 7, the forming anvil 110, the die assembly 160,the clinching assembly 200 and the driving member 222 may be orientedabout a central plane denoted by ‘Cp’ in the figures. A first directionD1 and an oppositely disposed second direction D2 may extendperpendicularly to the central plane Cp as shown. A third direction D3and an oppositely disposed fourth direction D4 lie within the centralplane Cp and are perpendicular to the first direction D1 and the seconddirection D2.

It is to be understood that terms such as ‘front’, ‘back’, ‘top’,‘bottom’, ‘horizontal’, ‘vertical’ and the like are used herein forillustrative purposes only. In actual use, the stapler 100 can beconfigured in almost any orientation, thus making terms such as ‘front’,‘back’, ‘top’, ‘bottom’, ‘horizontal’ and ‘vertical’ relative to theorientation of the stapler 100.

With continued reference to FIG. 7, the forming anvil 110 may include afirst member 112 and a second member 132. The first member 112 may havea forming corner 114 located at an intersection of a forming face 116and a vertical wall 118. The first member forming face 116 may define afirst forming face width ‘W1’ (FIG. 8). In one exemplary, non-limitingembodiment, the first forming face width W1 may be about 0.10 to 0.25inches. The first member forming corner 114 may take the form of a sharpcorner with minimal radius as depicted in the figures. The forming anvilfirst member 112 may have a mating face 120 oriented substantiallyparallel to the central plane Cp. The forming anvil first member 112 mayinclude a base portion 122. The base portion 122 may include provisionsfor accepting mechanical manipulation by any one of a variety of devicessuch as linear actuators, pneumatic cylinders, four-bar linkages, directcurrent or stepper motors, rack-and-pinion devices, hydraulics, or otherdevices. For illustrative purposes only, mechanical manipulation of thebase portion 122 and other elements of the stapler 100 will be describedas utilizing motors, such as direct current motors (not shown). Thefirst member 112 may be movably attached within the stapler 100 suchthat the first member 112 may move in the first direction D1 and thesecond direction D2. As can be appreciated, such movement of the firstmember 112 in the first direction D1 will move the mating face 120 awayfrom the central plane Cp. Alternatively, the first member 112 may bemoved in the second direction D2 to move the mating face 120 towards thecentral plane Cp.

With continued reference to FIG. 7, the forming anvil second member 132may have a forming corner 134 located at the intersection of a formingface 136 and a vertical wall 138. The second member forming face 136 mayhave a second forming face width ‘W2’ (FIG. 8). In one exemplary,non-limiting embodiment, the second forming face width W2 may be about0.10 to 0.25 inches. The second member forming corner 134 may take theform of a sharp corner with a minimal radius. The second forming member132 may have a mating face 140 oriented substantially parallel to thecentral plane Cp. The second forming member 132 may be provided with abase portion 142. The base portion 142 may include provisions foraccepting mechanical manipulation by any one of a variety of devices aspreviously described for moving the forming anvil first member 112. Thesecond member 132 may be movably attached within the stapler 100 suchthat the second member 132 may move in the second direction D2 and thefirst direction D1. Movement of the second member 132 in the seconddirection D2 may move the mating face 140 away from the central planeCp. Alternatively, the second member 132 may be moved in the firstdirection D1 to move the mating face 140 towards the central plane Cp.

With reference to FIG. 8, the forming anvil first member forming corner114 may be separated from the forming anvil second member forming corner134 by a forming anvil separation distance W3. Variations of thisforming anvil separation distance W3 result in variations of the staplecrown length L1 and the leg length L2 in a manner that will be describedin detail later herein.

With reference to FIG. 7, the die assembly 160 may include a firstmember 162 and a second member 182. The die assembly first member 162may have a forming corner 164 located at the intersection of a formingface 166 and a vertical wall 168. The vertical wall 168 has a widthdenoted by ‘W6’ (FIG. 9) that in one exemplary embodiment may be aboutthe width L4 (FIG. 5) of the preform 84 (e.g. 0.020 inches). The firstmember forming corner 164 may take the form of a sharp corner with aminimal radius. The die assembly first member 162 may have a mating face170 oriented substantially parallel to the central plane Cp. The firstmember 162 may include a base portion 172. The base portion 172 mayinclude provisions for accepting mechanical manipulation by any one ofthe variety of devices previously mentioned, such as a direct currentmotor. The first member 162 may be movably attached within the stapler100 such that the first member 162 may move in the first direction D1and the second direction D2. Such movement of the first member 162 inthe first direction D1 may move the mating face 170 away from thecentral plane Cp. Alternatively, the first member 162 may be moved inthe second direction D2 to move the mating face 170 towards the centralplane Cp. Furthermore, the first member 162 may be movable in the thirddirection D3 and the fourth direction D4. Such movement of the firstmember 162 in the third direction D3 may move the die assembly firstmember forming face 166 towards the forming anvil first member formingface 116. Alternatively, the first member 162 may be moved in the fourthdirection D4 to move the die assembly first member forming face 166 awayfrom the forming anvil first member forming face 116.

With continued reference to FIG. 7, the die assembly second member 182may have a forming corner 184 located at the intersection of a formingface 186 and a vertical wall 188. The vertical wall 188 has a widthdenoted by ‘W6’ (FIG. 9) that in one exemplary embodiment may be aboutthe width L4 (FIG. 5) of the preform 84 (e.g. 0.020 inches). The secondmember forming corner 184 may take the form of a sharp corner with aminimal radius. The die assembly second member 182 may have a matingface 190 oriented substantially parallel to the central plane Cp. Thesecond member 182 may include a base portion 192. The base portion 192may include provisions for accepting mechanical manipulation in a mannerpreviously described with respect to the die assembly first member 162.The second member 182 may be movably attached within the stapler 100such that the second member 182 may move in the second direction D2 andthe first direction D1. This movement may be dictated by the position ofthe forming anvil second member forming corner 134. Such movement of thesecond member 182 in the second direction D2 may serve to move themating face 190 away from the central plane Cp. Alternatively, thesecond member 182 may be moved in the first direction D1 to move themating face 190 towards the central plane Cp. Furthermore, the secondmember 182 may be movable in the third direction D3 and the fourthdirection D4. Such movement of the second member 182 in the thirddirection D3 may move the die assembly second member forming face 186towards the forming anvil second member forming face 136. Alternatively,the second member 182 may be moved in the fourth direction D4 to movethe die assembly second member forming face 186 away from the forminganvil second member forming face 136.

With reference to FIG. 8, the die assembly first member forming corner164 may be separated from the die assembly second member forming corner184 by a die assembly separation distance W4. The die assemblyseparation distance W4 may be varied during an adjustment step that willbe described later herein.

With reference to FIG. 7, the clinching assembly 200 may include a firstmember 202 and a second member 212. The clinching assembly first member202 may include a clinching detent 204 formed in a forming face 206. Thefirst member clinching detent 204 may have a generally circular profile.It is noted that other clinching devices may be utilized such as thosedescribed in U.S. Pat. No. 5,004,142, to Olesen which is herebyspecifically incorporated by reference for all that is disclosedtherein. The clinching assembly first member 202 may have a mating face208 oriented substantially parallel to the central plane Cp. The firstmember 202 may also include a base portion 210. The base portion 210 mayinclude provisions for accepting mechanical manipulation by any one ofthe variety of devices previously mentioned, such as a direct currentmotor. The first member 202 may be movably attached within the stapler100 such that the first member may move in the first direction D1 andthe second direction D2. Such movement of the first member 202 in thefirst direction D1 may serve to move the mating face 208 away from thecentral plane Cp. Alternatively, the first member 202 may be moved inthe second direction D2 to move the mating face 208 towards the centralplane Cp.

With continued reference to FIG. 7, the clinching assembly second member212 may have a clinching detent 214 formed in a forming face 216. Thesecond member clinching detent 214 may be substantially similar to thepreviously described first member clinching detent 204. The clinchingassembly second member 212 may have a mating face 218 orientedsubstantially parallel to the central plane Cp. The second member 212may include a base portion 220. The base portion 220 may includeprovisions for accepting mechanical manipulation in a mannersubstantially similar to that described with respect to the clinchingassembly first member 202. The second member 212 may be movably attachedwithin the stapler 100 such that the second member 212 may move in thesecond direction D2 and the first direction D1. Such movement of thesecond member 212 in the second direction D2 may serve to move themating face 218 away from the central plane Cp. Alternatively, thesecond member 212 may be moved in the first direction D1 to move themating face 218 towards the central plane Cp.

With reference to FIG. 8, the clinching assembly first member 202 may beseparated from the clinching assembly second member 212 by a clinchingassembly separation distance W5. The clinching assembly separationdistance W5 may be varied during an adjustment step that will bedescribed later herein.

With reference to FIG. 7, the driving assembly 230 may include a firstmember 232 and a second member 242. The driving assembly first member232 may be provided with a blade portion 234 and a base portion 236. Theblade portion 234 may be integrally formed on the base portion 236.Furthermore, the blade portion 234 may be provided with a drivingsurface 238 and a guide surface 239. The guide surface 239 may besubstantially perpendicular to the driving surface 238. The base portion236 may be further provided with a mating face 240 orientedsubstantially parallel to the central plane Cp. The base portion 236 mayinclude provisions for accepting mechanical manipulation by any one ofthe variety of devices previously mentioned, such as a direct currentmotor. The first member 232 may be movably attached within the stapler100 such that the first member 232 may move in the first direction D1and the second direction D2. Such movement of the first member 232 inthe first direction D1 may move the mating face 240 away from thecentral plane Cp. Alternatively, the first member 232 may be moved inthe second direction D2 to move the mating face 240 towards the centralplane Cp. Furthermore, the first member 232 may be movable in the thirddirection D3 and the fourth direction D4. Such movement of the firstmember 232 in the third direction D3 may move the driving assembly firstmember forming face 238 towards the clinching assembly first memberforming face 206. Alternatively, the first member 232 may be moved inthe fourth direction D4 to move the driving assembly first memberforming face 238 away from the clinching assembly first member formingface 206.

The driving assembly second member 242 may be provided with a bladeportion 244 and a base portion 246. The blade portion 244 may beintegrally formed on the base portion 246. Furthermore, the bladeportion 244 may be provided with a driving surface 248 and a guidesurface 249. The guide surface 249 may be substantially perpendicular tothe driving surface 238. The base portion 246 may be further providedwith a mating face 250 oriented substantially parallel to the centralplane Cp. The base portion 246 may include provisions for acceptingmechanical manipulation by any one of the variety of devices previouslymentioned, such as a direct current motor. The second member 242 may bemovably attached within the stapler 100 such that the second member 242may move in the first direction D1 and the second direction D2. Suchmovement of the second member 242 in the first direction D1 may move themating face 250 away from the central plane Cp. Alternatively, the firstmember 242 may be moved in the second direction D2 to move the matingface 250 towards the central plane Cp. Furthermore, the second member242 may be movable in the third direction D3 and the fourth directionD4. Such movement of the second member 242 in the third direction D3 maymove the driving assembly second member forming face 248 towards theclinching assembly second member forming face 216. Alternatively, thesecond member 242 may be moved in the fourth direction D4 to move thedriving assembly second member forming face 248 away from the clinchingassembly second member forming face 216.

With reference to FIG. 8, the driving assembly 230 may have a drivingassembly width denoted at ‘W7’ associated therewith. The seventh widthW7 is the distance between the first member guide surface 239 and thesecond member guide surface 249.

As illustrated in FIG. 9, the stapler 100 may be provided with theaperture 260. The aperture 260 is provided for supporting a staple in amanner that will be described later herein.

Having provided one exemplary embodiment of the stapler 100, a processof forming the staple 40 and clinching the stack 32 with the stapler 100will now be described. It should be noted that the immediately followingforming process describes forming and clinching steps for a relativelysmall stack 32 (e.g. four sheets of media). In a process described laterherein, the stapler 100 can be configured to form the staple 40 for arelatively thick stack 32 (e.g. twenty sheets of media).

Before describing exemplary forming and clinching operations in detail,a brief overview will now be provided. FIG. 9 shows an introduction stepwherein the staple preform 84 may be introduced to the stapler 100between the forming anvil 110 and the die assembly 160 (FIG. 9 shows aside view). FIG. 10 shows an adjustment step wherein the stapler 100 maybe configured for the desired leg length L2. FIG. 11 shows a formingstep wherein the staple 40 may be formed from the staple preform 84.FIGS. 12 and 13 show a clinching step wherein the staple 40 may bepositioned adjacent to the stack 32, driven through the stack 32 andhave the clinches 72, 74 formed therein, thereby securing the individualsheets of media of the stack 32.

With reference to FIG. 9, the introduction step may begin by feeding theplurality of preforms 83 from the cartridge 80 to the stapler 100. Suchintroduction of the preforms 83 may result in the preform 84 beinglocated between the forming anvil assembly 110 and the die assembly 160(a front view of the same is shown in FIG. 10). Furthermore, theintroduction of preform 84 may result in forming this preform only (andnot the adjacent preform 86). This introduction of the preform 84 mayoccur by advancing all of the preforms 83 from the cartridge 80. In oneembodiment, the preform 84 may remain attached to the adjacent preform86 while it is formed by the following process.

With reference to FIG. 10, the adjustment step may allow for varying thecrown length L1 by moving the forming anvil first and second members112, 132. In order to form a staple 40 with a crown length L1 of 0.625,the forming anvil separation distance W3 may be about 0.575. Theadjustment step may also require moving the die assembly first andsecond members 162, 182 to vary the die separation distance W4. Aspreviously mentioned, a description of the adjustment step will bedetailed later herein. In order to form the staple 40 with a crownlength L1 of 0.625, the die separation distance W4 may be about 0.685.The adjustment step may also require moving the driving assembly firstand second members 232, 242 to vary the driving assembly width W7. Inorder to form a staple 40 with a crown length L1 of 0.625, the drivingassembly width W7 may be about 0.685. These exemplary dimensions for theforming anvil separation distance W3, the die separation distance W4 andthe driving assembly width W7 are provided for descriptive purposesonly, it is noted that they may be altered according to staplerconfiguration, preform material and dimension, or other factors.

With reference to FIG. 11, after completing the adjustment step, theforming step may commence. During the forming step, the die assembly 160may move in the third direction D3 to process the preform 84 into thestaple 40. As shown in FIG. 11, the forming of the staple 40 may occurby forming the first bend 56 and the second bend 58. The first bend 56may be formed by bending the preform 84 between the forming anvil firstmember forming corner 114 and the die assembly first member formingcorner 164. The second bend 58 may be formed by bending the preform 84between the forming anvil second member forming corner 134 and the dieassembly second member forming corner 184. The forming of the preform 84may create the first and second bends 56, 58 with the first and secondlegs 52, 54 attached thereto. This creation of the legs 52, 54 convertsthe preform 84 into the staple 40.

After the forming step represented in FIG. 11 is complete, the clinchingstep represented in FIGS. 12 and 13 may occur. With reference to FIG.12, at the outset of the clinching step, the staple 40 may be advancedso that it extends beyond the forming anvil 110. Since the staple issuspended beyond the forming anvil 110, the staple 40 may be separatedfrom the adjacent preform 86. Such separation of the staple 40 from theadjacent preform 86 may occur by moving the driving member 222 in thethird direction D3 into contact with the staple crown 50. After beingseparated from the adjacent preform 86, the staple 40 may be positionedadjacent to the stack 32. Such positioning of the staple 40 adjacent tothe stack 32 may occur by moving the driving member 222 in the thirddirection D3 into contact with the staple crown 50. The staple 40 may beguided in the third direction D3 by a staple aperture (one variation ofa staple aperture is illustrated in FIGS. 17 and 18). As the drivingmember 222 moves the staple 40 through the staple aperture, the stapleends 62, 64 approach the stack 32.

As shown in FIG. 12, once the staple ends 62, 64 contact the stack 32,the driving member 222 may begin to push the staple ends 62, 64 into thestack 32. Such pushing of the staple ends 62, 64 into the stack 32creates holes in the stack 32. Ultimately, the legs 52, 54 penetratethrough the holes formed in the stack 32. As the staple legs 52, 54emerge from the stack 32, they are received by the clinching anvil 200.

After driving the staple 40 through the stack 32, the clinching anvil200 may be utilized in a process to fasten the stack 32 together. Theclinching anvil 200 must have the first member 202 and the second member212 separated by the clinching assembly separation distance W5, FIG. 12,based on the crown dimension L1 (FIG. 13). As previously mentioned, thecrown dimension L1 is a function of the thickness of the stack 32;therefore, the separation distance W5 is a function of the thickness ofthe stack 32.

With reference to FIG. 13, the clinching step may continue by contactingthe first leg end 62 with the clinching anvil first member clinchingdetent 204. The first member clinching detent 204 has a profile capableof forming the first leg end 62 into the clinch 72 while the drivingmember 222 urges staple 40 in the third direction D3. Forming of theclinch 72 may result in the staple end 62 being displaced adjacent to,or slightly into, the stack 32. By forming the clinch 72 in this manner,the relatively sharp end 62 is hidden so that it does not interfere withregular usages of the stack 32, such as distribution, reading, carrying,etc.

While forming the first leg clinch 72, the second leg clinch may besimultaneously formed. The second leg end 64 may meet the clinchinganvil second member clinching detent 214. The second member clinchingdetent 214 has a profile capable of forming the second leg end 64 intothe clinch 74 while the driving member 222 urges the staple 40 in thethird direction D3. Forming of the clinch 74 may result in the stapleend 64 being displaced adjacent to, or slightly into, the stack 32. Byforming the clinch 74 in this manner, the relatively sharp end 64 ishidden so that it does not interfere with regular usages of the stack32, such as those previously mentioned.

The immediately preceding forming and clinching process was directed toa relatively small stack 32 (e.g. four sheets of bond paper). In theevent that a thicker stack of media (e.g. twenty sheets of bond paper)is to be clinched, the staple 40 may be formed with a different leglength L2. When stapling this relatively thick stack 32, the crownlength L1 (FIG. 4) may be relatively small and thereby result in the leglength L2 being relatively large. By reducing the crown length L1, thelonger legs 52, 54 have a proper length protruding from the stack 32.This proper length of the legs 52, 54 is utilized for creating clinches72, 74 therefrom, respectively. The sum of crown length L1 and the twoleg lengths L2 is defined as the preform length L3 (FIG. 6) according tothe equation: L1+L2+L2=L3. In one exemplary, non-limiting embodiment,the crown length L1 may be about 0.25 inches while the leg dimension L2may be about 0.4375 inches for the relatively thick stack 32. It isnoted that in this exemplary embodiment, the equation L1+L2+L2=L3 issatisfied because 0.25+0.4375+0.4375=1.125 inches, wherein L1 is about0.25 inches and L2 is about 0.4375 inches.

With reference to FIG. 10, assuming that the stapler 100 is to beconfigured for the thicker stack 32 after being configured for therelatively thin stack, the forming anvil first and second members 112,132 may be moved such that the forming anvil separation distance W3(FIG. 10) is reduced during the adjustment step. Additionally, the dieassembly members 162, 182 may be moved to reduce the die separationdimension W4. The clinching anvil members 202, 212 may also be moved toreduce the clinching distance W5. After configuring the stapler to formthe staple 40 for the thicker stack 32, the process of forming thestaple 40 and clinching the stack 32 may commence.

The process of forming the staple 40 and clinching the stack 32 may beessentially the same as previously described. Such forming of the staple40 for the thicker stack 32 and stapling of the thicker stack 32 resultsin clinches 72, 74 that are hidden so that they do not interfere withregular usage of the stack 32, such as distribution, reading, carrying,etc. This process of determining the crown length L1 and leg length L2and forming staples having the desired lengths L1, L2 may continueindefinitely according to the thickness of the stacks to be fastened.

As an alternative to the stapler 100 having movable elements (e.g. theforming anvil 110, the die assembly 160 and the clinching anvil 200),the stapler 100 may be provided with two separate sets of elements. Afirst set of elements may include a forming anvil, a die assembly and aclinching anvil for a small staple having relatively short leg lengthsL2 (FIG. 1) for clinching relatively few pieces of paper. A second setof elements may include a forming anvil, a die assembly and a clinchinganvil for a large staple having relatively long leg lengths L2 (FIG. 1)for clinching relatively large number of pieces of paper. Thisalternative embodiment may be configured such that movement of the setsof elements place either the first set or the second set of elementsinto position to be utilized for forming and clinching the staple.

As an alternative to the immediately preceding embodiment, the separatesets of elements may include more than the two sets described. In thisregard, there may be several different sets of elements for forming avariety of staples. The selection of the elements to be utilized tofasten a particular stack may be determined by the thickness of thestack to be fastened. Furthermore, these elements may be configured suchthat movement thereof may place a particular set of elements into aposition where staples may be formed therewith. Such movement may be anytype of mechanical movement, such as linear movement or rotary movement.

In another alternative embodiment, the staple 40 may be formed with aplurality of preforms in order to minimize the possibility of ‘staplebuckling’. As used herein, staple buckling is defined a conditionwherein a force F required to drive a staple into a stack exceeds thebuckling capacity of the staple. With reference to FIG. 14, this staplebuckling condition is illustrated by the dashed lines representative ofthe staple legs 52, 54. If the first leg 52 buckles, the first leg 52may be crushed as represented by the dashed lines denoted by referencenumeral 52 b. In a similar manner, if the second leg 54 buckles, thesecond leg 54 may be crushed as represented by the dashed lines denotedby reference numeral 54 b. The potential for occurrence of the staplebuckling condition may increase as the staple leg length L2 increases.In order to minimize the propensity for buckling, a plurality ofpreforms may be formed and stapled as shown in FIGS. 15 and 16. Theforming of a plurality of preforms may be accomplished in a similarmanner to the method previously described. FIG. 15 shows amultiple-preform staple 42 formed from a plurality of preforms such aspreforms 84, 86, 88, 90. Such multiple-preform staple 42 may haveincreased resilience to buckling due to the increase in thecross-sectional area of the multiple-preform staple 42. FIG. 16 showsthe stack 32 clinched with the multiple-preform staple 42 shown in FIG.15.

As an alternative to the immediately preceding embodiment, when makingthe multiple-preform staple 42 shown in FIG. 15, the preforms 84, 86,etc. may remain adhered to each other. When forming the multiple-preformstaple 42, this adhesion between the preforms 84, 86, etc. is retainedrather than being disrupted when separating the preforms 83 from eachother. In order to retain the adhesion between the preforms 83, thepreforms 83 must be formed simultaneously (rather than forming onepreform at a time). In order to simultaneously form a plurality ofpreforms 83 at one time, the dimensions of the forming die assemblyfirst and second member 162, 182 may be varied to increase the width W6(FIG. 7) of the vertical walls 168, 188. Such adhesion together servesto minimize the potential for buckling by supporting each preform (e.g.84, 86, etc) with at least the adjacent preform. Adhesive utilized tohold the multiple-preform staple 42 together may be provided at time ofmanufacture of the preform supply, such as cartridge 80 (FIG. 6).

In another alternative embodiment, the aperture 260 (FIG. 9) of thestapler 100 may be configured as a variable staple aperture 300 (FIGS.17 and 18) through which staples (e.g. multiple-preform staple 42 andstaple 40) may pass after forming and prior to stapling. The variablestaple aperture 300 may be any one of a variety of configurations suchas the configuration shown in FIGS. 17 and 18. With reference to FIG.17, the variable staple aperture 300 may be configurable to accommodatefor one or more staples (such as multiple staple 42) and varying crownlengths L1. The variable staple aperture 300 may include a first member302, a second member 312, and a third member 320. The first member 302may include a first surface 304 and a second surface 306, both may guidethe multiple-preform staple 42. The first member first surface 304 maybe positioned by moving the first member 302 in a fifth direction D5 andan oppositely disposed sixth direction D6. This positioning of the firstmember 302 may result in the variable staple aperture 300 forming asuitable opening for the multiple-preform staple 42 to travel therethrough. Likewise, the first member second surface 306 may be positionedby moving the first member 302 in the first direction D1 and the seconddirection D2. This positioning of the first member 302 may result in thevariable staple aperture 300 forming a suitable opening for themultiple-preform staple 42 to travel there through. The second member312 may include a first surface 314 and a second surface 316, both mayguide the multiple-preform staple 42. The second member first surface314 may be positioned by moving the second member 312 in the fifthdirection D5 and the sixth direction D6. This positioning of the secondmember 312 may result in the variable staple aperture 300 forming asuitable opening for the multiple-preform staple 42. Furthermore, thesecond member second surface 316 may be positioned by moving the secondmember 312 in the first direction D1 and the second direction D2. Thispositioning of the first member 302 may result in the variable stapleaperture 300 forming a suitable opening for the multiple-preform staple42. The third member 320 may be formed on or adjacent to the forminganvil 130. The third member 320 may include a first surface 322 againstwhich the multiple-preform staple 42 may slide. The third member firstsurface 322 may be stationary. By moving the first and second members302, 312, the variable staple aperture 300 may be configured such thatany one of a variety of staples may pass there through, such asmultiple-preform staple 42 (FIG. 15) and staple 40 (FIG. 5). Thevariable staple aperture 300 may be utilized as a guide while thedriving assembly 230 (FIG. 7) moves the staple (e.g. 40, 42, etc.) tothe stack 32. This variable stapler aperture 300 may allow for a varietyof staple configuration to be moved within the stapler 100. FIG. 18shows a front view of the stapler 100 provided with the variable stapleaperture 300. As illustrated, the driving assembly width W7 (FIG. 8) mayessentially match the crown length L1 (FIG. 4) so that it can clear thevariable stable aperture first and second members 302, 312. By matchingthe driving assembly width W7 with the crown length L1, the drivingassembly driving faces 238, 248 push on the entire portion of the staplecrown 50 (FIG. 4).

In another exemplary embodiment illustrated in FIG. 19, the drivingassembly 230 may be provided with an adjustable driving assembly 340 toaccommodate the multiple perform staple 42. This adjustable drivingassembly 340 may be any one of a variety of configurations such as avariable plate assembly 342 configuration illustrated in FIG. 19. Eachof the driving assembly members 232, 242 (FIG. 7) may be provided witthe variable plate 342. Once exemplary configuration of the variableplate assembly 342 will now described as being incorporated into thesecond member 242; it is to be understood that the first member 232 mayalso be provided with the variable plate assembly 342. The variableplate assembly 342 configuration may be provided with a first plate 344,a second plate 346, a third plate 348 and a fourth plate 350. The plates344, 346, 348 and 350 may be provided with driving surfaces such asdriving surfaces 354, 356, 358 and 360, respectively. The plate drivingsurfaces 354, 356, 358 and 360 may be selectively positioned such thatthey are coplanar with the driving surface 248. The variable plateassembly 342 may be further provided with an actuator 370 and asequential ramp 372. The variable plate assembly may be further provideddisplacement element such as a linear actuator 376. The linear actuator376 may be activated to displace the sequential ramp 372. The sequentialramp 372 may move the plates 344, 346, 348 and 350 adjacent to thedriving assembly second member blade portion 244. In use, the adjustabledriving assembly 340 may allow for the multiple preform staple 42 to beprovided with varying number of staples (such as the five-staplemultiple preform staple 42 illustrated in FIG. 19). This adjustabledriving assembly 340 allows for the entire crown-portion of the multiplepreform staple 42 to be pushed evenly by the driving surfaces 248, 354,356, 358 and 360.

In another exemplary embodiment, the stapler 100 may be provided as acomponent within an imaging apparatus 10, such as a printer. Withreference to FIG. 20, a schematic diagram depicts a simplified side viewof the exemplary imaging apparatus 10. This exemplary imaging apparatus10 may include the stapler 100. The imaging apparatus 10 may include amain body 12 and a sorter attachment 14. The main body 12 may include asupply of sheets of one or more types of media 16, such as paper. Thesheets of media 16 may be moved via a media path from the supply ofsheets to an image forming section 18, where an image may be formedthereon. The image forming section 18 may be any type of imaging deviceknown to those skilled in the art, such as a digital imaging system.

The imaging apparatus main body 12 may also include a user input station20 which can include actuators such as buttons 22. The user inputstation 20 may also include a display device 24 that allows the imagingapparatus 10 to provide information to the user. The imaging apparatus10 may also include a controller 26 which can receive instructions viathe user input station 20 and can control the operation of the imageforming section 18, the stapler 100, or other components of the imagingapparatus 10.

The imaging apparatus sorter attachment 14 may include a plurality ofoutput trays 28, such as output tray 30. The output trays 28 may allowfor multiple copies of a document to be separated for post imagingprocessing, such as stapling. The sorter attachment output tray 30 isshown holding a stack 32. As used herein, the term stack 32 is definedas a plurality of sheets of media, such as media 16. This stack 32 maydefine a thickness ‘T’ as shown in FIG. 20.

The sorter attachment 14 may include the stapler 100. In one exemplaryembodiment, the stapler 100 may be configured to move somewhatvertically in the sorter attachment 14 via a drive mechanism 34. Thedrive mechanism 34 may allow the stapler 100 to selectively access anyof the output trays 28. When selectively accessing one of the outputtrays 28, the stapler 100 may use the previously described process forclinching the stack 32 located therein.

It should be noted that the actual thickness of the stack 32 may bemonitored by the controller 26. In this exemplary embodiment, thecontroller 26 may track the quantity of sheets, thickness and/or type ofmedia processed by the imaging apparatus 10 and placed in one of theoutput trays 28. Such tracking may be utilized by the controller 26 todetermine the configuration best-suited for the particular stackthickness T. This determination may be made by a crown-dimensionalgorithm associated with the controller 26. One exemplarycrown-dimension algorithm may comprise multiplying the paper thicknessby a predetermined constant to obtain the staple crown length L1. Forexample:L 1=C*T; where,

-   -   L1 is the staple crown length;    -   C is the predetermined constant; and,    -   T is the thickness of the stack.

These various embodiments and variations thereof may be implemented in astapler to ensure proper stapling of stacks of media while utilizing theconvenience of prepackaged preforms.

While illustrative embodiments have been described in detail herein, itis to be understood that the concepts may be otherwise variouslyembodied and employed and that the appended claims are intended to beconstrued to include such variations except insofar as limited by theprior art.

1. A stapler of the type including a forming die that cooperates with a forming anvil to bend a staple preform into a staple having at least a pair of legs connected by a crown portion extending transversely to said pair of legs, comprising: said forming die having at least a first forming die member and a second forming die member; said forming anvil having at least a first forming anvil member and a second forming anvil member; wherein said first forming die member is moveable relative to said second forming die member; and wherein said first forming anvil member is moveable relative to said second forming anvil member.
 2. The stapler of claim 1 and further comprising: a driving assembly comprising a first driving assembly member and a second driving assembly member; wherein said first driving assembly member is moveable relative to said second driving assembly member.
 3. The stapler of claim 1 and further comprising: a clinching anvil comprising a first clinching anvil member and a second clinching anvil member; wherein said first clinching anvil member is moveable relative to said second clinching anvil member.
 4. The stapler of claim 1 wherein: said crown portion of said staple extends longitudinally in a first direction; said first forming die member is moveable relative to said second forming die member in said first direction.
 5. The stapler of claims and further wherein: said stapler includes at least a first operating condition and a second operating condition; wherein, in said first operating condition: said stapler is configured to form at least a first staple having a first crown length; at least a portion of said first forming die member is at a first distance from at least a portion of said second forming die member: wherein, in said second operating condition: said stapler is configured to form at least a second staple having a second crown length; said at least a portion of said first forming die member is at a second distance from said at least a portion of said second forming die member; wherein, said first crown length differs from said second crown length by a first amount; wherein, said first distance differs from said second difference by said first amount.
 6. A stapler of the type including a forming die that cooperates with a forming anvil to bend a staple preform into a staple having at least a pair of legs connected by a crown portion extending longitudinally in a first direction that is transverse to said pair of legs, comprising: said forming die having at least a first forming die member and a second forming die member; wherein said first forming die member is moveable relative to said second forming die member in said first direction.
 7. The stapler of claim 6, and further comprising: a driving assembly comprising a first driving assembly member and a second driving assembly member; wherein said first driving assembly member is moveable relative to said second driving assembly member in said first direction.
 8. The stapler of claim 6 and further comprising: a clinching anvil comprising a first clinching anvil member and a second clinching anvil member; wherein said first clinching anvil member is moveable relative to said second clinching anvil member in said first direction.
 9. The stapler of claim 6 and further wherein: said stapler includes at least a first operating condition and a second operating condition; wherein, in said first operating condition: said stapler is configured to form at least a first staple having a first crown length; at least a portion of said first farming die member is at a first distance from at least a portion of said second forming die member; wherein, in said second operating condition: said stapler is configured to form at least a second staple having a second crown length; said at least a portion of said first forming die member is at a second distance from said at least a portion of said second forming die member; wherein, said first crown length differs from said second crown length by a first amount; wherein, said first distance differs from said second difference by said first amount.
 10. The stapler of claim 6 wherein; said forming anvil having at least a first forming anvil member and a second forming anvil member; wherein said first forming anvil member is moveable relative to said second forming anvil member in said first direction.
 11. A method of creating a stapled document with a stapler of type including a forming die that cooperates with a forming anvil to bend a staple preform into a staple having at least a pair of legs connected by a crown portion extending longitudinally in a first direction that is transverse to said pair of legs, said method comprising: providing said forming die having at least a first forming die member and a second forming die member; forming at least one image on a sheet of media of a stack; presenting said stack to said stapler; determining a desired crown dimension for a staple, forming said staple comprising said crown dimension by moving said first forming die member relative to said second forming die member in said first direction; and stapling said stack with said staple, thereby creating said stapled document.
 12. The method of claim 11 and further comprising: providing said forming anvil having at least a first forming anvil member and a second forming anvil member; wherein said forming said staple comprising said crown dimension further comprises moving said first forming anvil member relative to said second forming die member in said first direction. 